EP2974813A1 - System and method for the generative production and/or repair of components - Google Patents

Abstract

The present invention relates to a plant for the generative production and / or repair of components, in particular of gas turbines, with a solidifying agent (3) for layered, local, especially optical, thermal and / or chemical, solidifying, in particular pulverulent, granular and / or liquid, material, and an electrodeposition (1.1, 7-10) for the electrostatic deposition of particles (6) and / or gas from a region between a to be consolidated and / or solidified layer (2.1) of the material and the solidifying agent (3) and a method for the generative production and / or repair of components, in particular of gas turbines, by means of such a system.

Description

The present invention relates to a system and a method for the generative production and / or repair of components, in particular gas turbines.

In particular, complex and / or highly stressed components such as blades of gas turbines can advantageously be manufactured and repaired generatively or additively. Here, material is consolidated locally in layers and bonded to an adjacent layer of already solidified material. In order to produce a new component, while a first layer is solidified on a support, from which it is released after the manufacture of the component. To repair an existing component, it is placed on the carrier and a first layer is solidified on the component.

In particular, by arranging a new layer of material to be consolidated and / or by solidifying it, particles and / or gas can reach the area between the layer of material to be consolidated or solidified and a solidifying agent. For example, when applying and / or distributing powdery material particles can be whirled up. Additionally or alternatively, for example, smoldering may occur during solidification. This can condense between the layer and the solidifying agent to particles.

Likewise, other particles, such as dust or the like, and / or gas may also enter the region between the layer and the solidifying agent from the environment.

Such particles and such gas may interfere in particular with an action on the solidifying agent by the solidifying agent, for example by deflecting and / or reflecting a laser beam. Additionally or alternatively, they may also affect a layer of the material to be consolidated or solidified, for example, inclusions therein or a cover layer formed thereon or the like. An object of an embodiment of the present invention is to improve the generative production and / or repair of components.

This object is achieved by a system having the features of claim 1 and a method having the features of claim 8. Advantageous embodiments of the invention are the subject of the dependent claims.

According to one aspect of the present invention, a plant for the generative production and / or repair of components, in particular of gas turbines, has a solidifying agent for the layered and local solidification of material to be consolidated.

The material to be consolidated is powdery or grainy in one embodiment. Equally, it can also be liquid, in particular pasty. In one embodiment, the solidification agent can act on the material optically, preferably by a light source, in particular a laser, and thereby solidify or be set up for this purpose. Likewise, in one embodiment, the solidification agent can act on the material thermally, preferably by a heating or cooling medium, and thereby solidify or be set up for this purpose. Likewise, in one embodiment, the solidification agent may chemically apply, and thereby solidify, the material to the material chemically, preferably through a printer head.

In one embodiment, the system has a receptacle for the material to be consolidated, in particular with material to be consolidated. In a further development, the receptacle has a, in particular frame-like, container for the material to be consolidated, in particular with material to be consolidated, in particular a powder bed. Additionally or alternatively, the recording in a further development on a support on which in one embodiment, a first layer which is released after the manufacture of the component from the carrier, or an already existing component is arranged, or provided for this purpose or set up is. Carrier and container are adjustable in one embodiment relative to each other, so as to arrange each new layers to be consolidated material. In particular, the carrier may be in the container, in particular stationary, to be moved or moved. Similarly, the container can be moved or moved to the, in particular stationary, carrier.

In one embodiment, the plant has a layer means for successively arranging layers of the material to be solidified on layers of already solidified material. In one development, the layer means has an output means for dispensing material to be solidified, in particular a further container which is preferably movable and / or has a closable dispensing opening. Additionally or alternatively, the layer means in a development on, preferably movable, distribution means for distributing material to be solidified to a layer to be solidified of the material, in particular a movable rake, squeegee, spatula, slide, scraper or the like. Preferably, dispensing and / or dispensing means are adjustable relative to the receptacle, in particular the container and / or carrier.

According to one aspect of the present invention, the system has an electrodeposition means for the electrostatic precipitation of particles and / or gas from a region between a layer to be solidified and / or solidified of the material and the solidification agent, in particular a region between the receptacle and the solidification agent.

By such a Elektroabscheidemittel, which is known in the art in particular of electrical (dust) filters, electrical gas cleaning, electrostat ("electrostatic precipitator") or electric (dust) separators, can disturbing particles and / or interfering gas from the field between a layer of the material and the solidifying agent that is at least partially still to be consolidated and / or at least partially solidified. As a result, in one embodiment, a disturbance of an application of material to be consolidated by the solidifying agent by such particles or such gas can be reduced, preferably at least substantially prevented. Additionally or alternatively, in one embodiment, an impairment of a to be solidified and / or solidified layer of the material reduced by such particles or such gas, preferably at least substantially prevented.

In one embodiment, the electrodeposition agent electrostatically separates particles and / or gas, or is provided or furnished for this purpose, which arrive in the area by arranging a new layer of material to be consolidated and / or by solidifying it, in particular fluidized particles Material and / or, in particular condensed into particles, smut, which arises when solidifying the material. Additionally or alternatively, in one embodiment, the electro-precipitant separates electrostatically from other particles and / or other gas, or is provided for this purpose, for example, dust or the like from the environment.

In one embodiment, the electrodeposition agent electrostatically separates particles or is adapted for this purpose, their size and / or mass, in particular maximum or average, not more than half, in particular not more than 10% of a, in particular maximum or average, size or mass of to be solidified, in particular granular or powdery, material and / or at most 0.1 mm, in particular at most 10 microns, in particular condensed to particle smoke, which is formed during solidification. As a result, on the one hand disturbing particles can advantageously be removed while, on the other hand, the material to be consolidated itself is not or only slightly influenced.

In one embodiment, the electrodeposition agent has a one-part or multi-part deposition electrode and a one-part or multi-part counterelectrode, in particular a spray electrode. The deposition and / or the counterelectrode may in particular be arranged laterally and / or above or on a side opposite the layer from the region between the layer to be consolidated and / or solidified and the solidification agent from which the particles and / or the gas are to be deposited , Be arranged, in particular to limit this range. In particular, they may each comprise one or more tubes or, in particular, flat plates. In particular, plates can be advantageously cleaned and / or an advantageous one Realizing flow of the particles to be separated or of the gas to be separated.

In one embodiment, the counterelectrode is / are spaced from the deposition electrode by at least 1 cm and / or at most 100 cm, in particular at most 50 cm, preferably at most 10 cm. In one embodiment, the electrodeposition means has a voltage source for applying a direct or alternating voltage between the deposition and counterelectrode, in particular of at least 15 kV, in particular at least 25 kV, and / or at most 85 kV, in particular at most 75 kV, and in a further development , In particular programmable, control means for controlling a voltage applied between the deposition and counter electrode voltage. In the present case, controlling is understood as meaning, in particular, also a regulation or presetting of a one-dimensional or multidimensional manipulated variable on the basis of a predefined setpoint value and a detected, recirculated actual variable.

In one embodiment, the control means controls a voltage applied between the deposition electrode and the counterelectrode, in particular as a function of a local solidification of a layer of the material and / or a particularly measured concentration of particles to be separated and / or gas to be deposited in the region or is set up for this purpose.

In particular, the control means may apply or be adapted to apply a voltage for separating particles and / or gas when a measured concentration of particulate matter to be deposited exceeds a predetermined limit, or during a solidification of a layer of the material and / or for a predetermined time before and / or after. Additionally or alternatively, in one embodiment, the control means may specify an amount of applied voltage depending on a measured concentration of particulate matter to be separated and / or gas to be deposited in the area, for example, proportionally thereto.

In one embodiment, one or more electrodes, in particular the above-mentioned deposition and / or counter electrode, stationary or relative to the recording stationary.

In one development, one or more electrodes, in particular the abovementioned deposition and / or counterelectrode, are stationary or stationary relative to the container of the receptacle. In particular, such an electrode can have a container wall of the container or a container wall of the container can form such an electrode, preferably by electrically connecting the container wall to the voltage source. Likewise, a container-fixed electrode may be electrically insulated from a container wall of the container. Additionally or alternatively, in one development, one or more electrodes, in particular the abovementioned deposition and / or counterelectrode, are stationary or stationary relative to the support of the receptacle. In particular, the carrier can be electrically connected to the voltage source or be. Thus, in one embodiment by the voltage source, a potential difference or voltage between an electrically insulated against a container wall of the container electrode, in particular a one- or multi-part deposition or counter electrode, and an electrically conductively connected to the container or the carrier electrode, in particular one one or multi-part counter or deposition electrode applied, in particular controlled by control means, be or be.

Similarly, one or more electrodes of the electrodeposition, in particular the above-mentioned deposition and / or counter electrode, relative to the recording, in particular motor, be adjusted or adjusted. As a result, in one embodiment, for example, interference with a layer means of the system can be avoided. Additionally or alternatively, the electrostatic deposition or the electric field caused by the applied voltage can thus be predetermined, in particular changed. Thus, for example, by reorienting the deposition electrode, a flow of particles or gas to be deposited can be varied and / or the strength of the electric field can be changed by removal from the counterelectrode and thus adapted to the process.

In a further development, an adjustable electrode is solidifying agent-fixed or arranged on the solidifying agent. In this way, the electrode can advantageously join in a movement of the adjusting means, wherein the solidifying agent-fixed electrode in turn can be fixed to the adjusting means adjustable or stationary.

In one embodiment, a cleaning agent of the electrodeposition agent cleans a deposition electrode of the electrodeposition agent or is provided or furnished for this purpose. The cleaning agent may in particular be cleaned or set up or provided for this purpose continuously, for example by rinsing, or intermittently, for example by tapping with a hammer mechanism or the like, before, during and / or after the solidification of a layer.

In one embodiment, an ionization agent of the electrodeposition means ionizes gas in the region between a layer of material to be consolidated and / or solidified and the solidifying agent from which particles and / or gas are to be deposited, in particular before, during and / or after locally strengthening this layer or is intended or furnished for this purpose. The ionization agent may in particular have the deposition and / or spray electrode, which ionize the gas by means of a correspondingly applied voltage, which in turn can charge particles electrically and thus enhance their electrostatic deposition. If such a reinforcement is not required, in particular the particles or the gas, for example by solidification, are already charged, such ionization can also be dispensed with. Similarly, the ionization can also be done by a different ionizer from the separator and counter electrode or ionizer. Accordingly, the ionization agent may comprise the deposition and / or spray electrode and / or a different ionizer.

According to one aspect of the present invention, for the generative production and / or repair of components, in particular of gas turbines, by means of a plant described here successively or repeatedly, in particular in a conventional manner layers of material on layers of already solidified material arranged, in particular by the Layering agent, and this by the solidifying agent locally bonded and connected to the respective adjacent layer of already solidified material.

The electrostatic precipitates before, during and / or after the local solidification of one or more of these layers electrostatic particles and / or gas from the area between a to be solidified and / or solidified layer of the material and the solidifying agent. In particular, the solidification and the deposition can take place successively or in parallel, wherein the deposition can additionally take place before and / or after solidification. It is thus advantageously possible, for example, to deposit foreign particles and / or particles introduced by the dispensing and / or distribution by means of deposition prior to solidification, in order to reduce, or at least substantially avoid, a disturbance already at the beginning of solidification. By depositing in parallel to the solidification, it is advantageously possible to reduce, preferably at least substantially avoid, a disruption of the solidification due to the solidification, especially of fumes, condensed into particles. By a subsequent solidification subsequent deposition can be advantageously reduced, preferably at least substantially avoided, be deposited on solidification, especially condensed to particles, smoke and / or foreign particles.

Fig. 1

eine Anlage bei der generativen Herstellung oder Reparatur eines Bauteils nach einer Ausführung der vorliegenden Erfindung; und

Fig. 2

eine Anlage bei der generativen Herstellung oder Reparatur nach betriebsinterner Praxis.

Further advantageous developments of the present invention will become apparent from the dependent claims and the following description of preferred embodiments. This shows, partially schematized:

Fig. 1

a plant in the generative production or repair of a component according to an embodiment of the present invention; and

Fig. 2

a plant in generative production or repair according to in-house practice.

Fig. 2 shows for explanatory purposes an investment in the generative production or repair of a component according to in-house practice.

The plant has a receptacle with a container 1 to be solidified with material 2 and a movable relative to the container carrier 4, a solidifying agent in the form of a movable laser head 3 for layerwise, local solidification of the material to be solidified, and a layer means for sequentially arranging layers the material to be solidified on layers of already solidified material with a relative to the receptacle movable output and distribution means 5 for dispensing and distributing material to be solidified to a layer to be solidified of the material.

In successive steps, the support 4 is repeatedly lowered by one layer thickness in the container 1, a new layer of material to be solidified is arranged and distributed on the last solidified layer by the layering agent 5, and locally visually impinged and thereby solidified by the solidifying agent 3 connected to the adjacent, last solidified layer.

During solidification, there is formed smoke which condenses in the form of particles 6 in the region between the uppermost layer 2.1 of the material and the solidifying agent in the beam path of the laser 3, which still has to be partially solidified or partially solidified, thus impairing solidification. This is in Fig. 2 indicated by an undesirable widening of the laser beam.

In order to reduce, preferably at least substantially prevent, such an interference, an electrodeposition agent of a plant according to an embodiment of the present invention electrostatically separates particles 6 from the region between the uppermost layer 2.1 of the material 2 which is partially to be consolidated or partially already solidified and the solidifying agent 3, as shown in FIG Fig. 1 is shown. In this case, corresponding features are identified by identical reference numerals, so that reference is made to the above description and will be discussed below only differences. The output and distribution means 5 is in Fig. 1 not shown, it can for example be arranged in alternation with the Elektroabscheidemittel to the container 1. In another embodiment, it may be in his in Fig. 2 indicated non-use or parking position also be arranged inside or outside of a subsequently explained deposition electrode 7 of the electrodeposition means or be.

The electrodeposition means comprises the already mentioned deposition electrode 7. In the exemplary embodiment, this surrounds in an annular manner the region between the uppermost layer 2.1 of the material 2 and the solidifying agent 3, which still has to be partially solidified or partially solidified. In a modification not shown, the precipitation electrode may, for example, also comprise one or more plates which are in Fig. 1 are arranged laterally next to and / or above the container 1 and are electrically insulated against this.

The Elektroabscheidemittel further comprises a container-fixed counter electrode, which is formed in the embodiment by a container wall 1.1 of the container 1 for limiting the material to be solidified 2.

Furthermore, the electrodeposition means comprises a voltage source 8 for applying a voltage between the deposition and counterelectrode 7, 1.1 and a control means 9 for controlling this voltage.

The deposition electrode 7 may be fixed to the container or fixed to the container 1 or, in particular by the control means 9, be adjustable relative to the container 1. In a modification, not shown, the deposition electrode 7 is solidifying agent fixed or arranged on the laser head 3 and is moved by it.

The electrodeposition means further comprises a cleaning agent in the form of a hammer mechanism 10 for the intermittent cleaning of the deposition electrode 7 of particles 6.1 deposited on the deposition electrode.

Separating and counterelectrode 7, 1.1 form an ionizing agent of the electrodeposition means for ionizing gas in the region between the uppermost, partly still to be consolidated or partially already solidified layer 2.1 of the material 2 and the solidifying agent. 3

Before, during and / or after the local solidification of the layer 2.1 of the material 2 by applying a corresponding voltage between the deposition and counter electrode 7, 1.1 by the control means 9 by means of the voltage source 8 gas in the area between the top, partially still to solidifying or partially already solidified layer 2.1 of the material 2 and the solidifying agent 3 ionized and thereby electrically charged particles 6 electrostatically deposited on the deposition electrode 7. The hammer mechanism 10 intermittently cleans the precipitation electrode 7 of particles 6.1 deposited thereon, which fall downwards into a collection bunker 11.

Although exemplary embodiments have been explained in the foregoing description, it should be understood that a variety of modifications are possible. For example, instead of particles 6, gas can also be electrostatically separated.

It should also be noted that the exemplary embodiments are merely examples that are not intended to limit the scope, applications and construction in any way. Rather, the expert is given by the preceding description, a guide for the implementation of at least one exemplary embodiment, with various changes, in particular with regard to the function and arrangement of the components described, can be made without departing from the scope, as it turns out according to the claims and these equivalent combinations of features.

LIST OF REFERENCE NUMBERS

1

container

1.1

Container wall (counter / spray electrode)

2

material

2.1

topmost layer to be consolidated, partially already solidified

3

Laser head (solidifying agent)

4

Carrier (shift agent)

5

Dispensing and distribution means (shift agent)

6

particle

6.1

separated particles

7

deposition electrode

8th

voltage source

9

control means

10

Hammer mechanism (cleaning agent)

11

collecting bin

Claims (13)

Plant for the generative production and / or repair of components, in particular of gas turbines, with a solidifying agent (3) for layered, local, in particular optical, thermal and / or chemical, solidification of, in particular powdery, granular and / or liquid, material, characterized by
an electrodeposition means (1.1, 7-10) for the electrostatic precipitation of particles (6) and / or gas from a region between a layer (2.1) of the material to be consolidated and / or solidified and the solidifying agent (3). Installation according to the preceding claim, characterized by a receptacle (1, 4) for the material (2), in particular with a container (1) and / or a carrier (4), and / or a layer means (5) for sequentially arranging to be consolidated layers of material on layers of already solidified material, in particular with a, in particular relative to the recording adjustable, output means (5) for outputting material to be solidified and / or distribution means (5) for distributing material to a layer to be solidified of the material , Plant according to the preceding claim, characterized in that at least one electrode (1.1, 7) of the electrodeposition means is receptive, in particular container or carrier-proof, or relative to the receptacle. Plant according to the preceding claim, characterized in that an adjustable electrode is solidifying agent. Installation according to one of the preceding claims, characterized in that the Elektroabscheidemittel a one- or multi-part deposition electrode (7), a one- or multi-part counter electrode (1.1), which is spaced from the deposition electrode in particular at least 1 cm and / or at most 100 cm, a voltage source (8) for applying a DC or AC voltage between the deposition and counterelectrode, in particular of at least 15 kV and / or at most 85 kV, and / or a control means (9) for controlling a voltage applied between the deposition and counter electrode voltage. Installation according to the preceding claim, characterized in that the Elektroabscheidemittel a cleaning means (10) for, in particular continuous or intermittent, cleaning of the deposition electrode (7). Installation according to one of the preceding claims, characterized in that the Elektroabscheidemittel an ionization (1.1, 7-9) for ionizing gas in the region between a to be consolidated and / or solidified layer (2.1) of the material and the solidification agent (3) , Method for the generative production and / or repair of components, in particular of gas turbines, by means of an installation according to one of the preceding claims, wherein successive layers of, in particular pulverulent, granular and / or liquid, material are arranged on layers of already solidified material and the solidifying agent ( 3) these locally, in particular optically, thermally and / or chemically, solidifies and connects with the adjacent layer already solidified material, and wherein the Elektroabscheidemittel (1.1, 7-10) electrostatically particles (6) and / or gas from the area between a to be consolidated and / or solidified layer (2.1) of the material and the solidifying agent (3) separates. Method according to the preceding claim, characterized in that before, during and / or after the local solidification of a layer of the material, the electro-deposition agent electrostatically separates particles and / or gas from the region. Method according to one of the preceding claims, characterized in that a control means (9) of the electrodeposition means controls a voltage applied between a deposition electrode and a counterelectrode (7, 1.1) of the electrodeposition means, in particular depending on a local solidification of a layer of the material and / or one, in particular measured, Concentration of particles to be separated and / or gas to be separated in the area. Method according to the preceding claim, characterized in that a cleaning agent (10) of the electrodeposition means a separating electrode (7) of the electrodeposition, in particular continuously or intermittently, cleans. Method according to one of the preceding claims, characterized in that an ionizing agent (1.1, 7-9) of the electrodeposition means ionizes gas in the region, in particular before, during and / or after the local solidification of a layer of the material. Method according to one of the preceding claims, characterized in that at least one electrode of the electrodeposition, in particular before, during and / or after the local solidification of a layer of the material, relative to the receptacle (1, 4) for the material (2) is adjusted ,

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